Article sorting system and method

ABSTRACT

The conveyor sorting system and method are provided. The system includes a conveyor for transporting articles along a predetermined path, and a pair of opposing chutes for receiving articles directed from the conveyor by a sorting device having a single paddle. The chutes are in communication with one another so that articles directed into either chute from the conveyor are directed to a common discharge end. In this regard, the single paddle of the present invention is operable to direct consecutively-spaced articles to opposing chutes that lead to the common discharge end.

FIELD OF THE INVENTION

[0001] The present invention relates to sorting systems, and moreparticularly to conveyor sorting systems wherein articles are directedoff the conveyor toward a desired location.

BACKGROUND OF THE INVENTION

[0002] Systems and methods for sorting articles are generally known andpracticed in many forms. A conventional manual sorting system includes aconveyor for transporting packages or articles to laborers or lineworkers, who physically remove or redirect the articles to a desiredlocation according to a predetermined schedule or predeterminedparameters, such as sorting by article description, size, etc. This typeof system, however, is slow, labor intensive, and expensive.

[0003] More recently, automatic sorting systems have been developed thatprove to be much faster and efficient than the manual system describedabove. Automatic sorting systems typically utilize a conveyor, such aspowered rollers or a continuous belt, that directs articles along a pathof travel. In order to redirect the articles, one conventional systemprovides means for lifting the articles off the conveyor and depositingthe articles in a desired location. However, these systems are also slowand expensive. Another conventional automatic sorting system providesmeans for lifting a portion of the conveyor in order to slide thearticles off one side of the conveyor to the desired location. Thesesystems are also expensive and cumbersome due to the hydraulic orpneumatic lifting mechanisms utilized in these systems.

[0004] A more common conventional automatic sorting system includesmeans for pushing the articles off the conveyor to the desired location,such as a storage bin, tote, or other conveyor. A plurality of “pushers”act unidirectionally, meaning that the pushing action of each pusher islimited to one direction followed by a recoil or return action to thepusher's initial position before the next pushing action can occur.These systems, however, are also limited in speed or “throughput”because the articles must be spaced far enough apart to allow for thepusher to return to its initial position between each pushing action.This spacing requirement is true regardless of the number of pushersused in a particular system, as the articles must be spaced far enoughapart so that subsequent articles are not hit by the returning pushers.

[0005] In order to decrease the spacing of the articles on the conveyor,which thereby increases throughput, automatic sorting systems have beendeveloped having sorting devices that utilize a plurality of pushersextending from a rotating continuous belt positioned above the conveyorso that the pushers direct articles off the conveyor in a repeatedfashion. Such a system is shown in French Patent 2620-054 to Ritoux(“The French Patent”) and Japanese Patent 5-178451 to Sakagami (“TheJapanese Patent”). These systems, however, require multiple pushers ineach sorting device in order to direct the articles off the conveyor,which adds complexity.

[0006] Another problem with these systems is that the systems aredesigned to push several articles off one particular side of theconveyor. In particular, the advantage stated by the French Patentstates that the “ejectors” or paddles “do not need to return to theirrest positions after operation,” which according to the drawings of theFrench Patent means that the paddles travel a full revolution for eachpushing operation. Indeed, the paddles of the French Patent and theJapanese Patent act as unidirectional pushers that push consecutivearticles off only one side of the conveyor. Although the Japanese Patentshows opposing ramps for receiving articles directed from the conveyor,each ramp is provided for receiving a plurality of consecutive articles.In this regard, neither the French Patent nor the Japanese Patent teachor suggest sorting consecutive articles to opposite sides of theconveyor, as doing so would not utilize the multiple paddle feature ofthese patents. Even if the systems described in the French Patent andthe Japanese Patent were operated to sort consecutive articles toopposite sides of the conveyor, these patents do not show any furthersorting operations.

[0007] Another problem with conventional sorting systems that directarticles off either side of the conveyor is that the articles are sortedto distinct locations even if the sorted articles are the same. Forexample, articles sorted by a first sorter to one side of the conveyorare often directed to a first storage bin or tote, and articles sortedby a second sorter to the opposite side of the conveyor are directed toa second tote, even if the second sorter is immediately downstream ofthe first sorter. This creates production difficulties by requiringmultiple totes for the same product or products meeting the sameparameters.

[0008] Yet another problem with conventional sorters is that certainarticles, such as thin, flat, or other irregularly shaped articles, areoften missed by the pushers or sorters. In particular, these articlesare so low that the pushers cannot sufficiently engage the articles tosweep them off the conveyor. Although it is possible to drag the pusheracross the conveyor to sweep the articles off the conveyor, this is notdesirable due to the resulting high friction built up as well asincreased wear on the conveyor and pusher. Yet another problem withconventional sorters is that round or cylindrical articles are difficultor impossible to sort because of their tendency to roll off theconveyor.

[0009] Accordingly, there is a need to provide a sorting system thatincludes a simple sorting device for rapidly sorting articles. There isalso a need to sort articles so that the number of totes for receivingthe articles is minimized. Further, there is a need to differentiate andsort articles according to a particular requirement or condition so thatthe articles can be sorted into the desired locations. Further still,there is a need to provide a sorting system and a method for sortingarticles wherein a wide variety of objects, including round,cylindrical, or flat articles can be easily sorted.

SUMMARY OF THE INVENTION

[0010] These and other needs are provided, according to the presentinvention, by a sorting system comprising a sorting device having asingle, double-sided paddle for directing articles off either side ofthe conveyor. Advantageously, the spacing between the articles on theconveyor is substantially less than conventional systems, which therebyallows for greater throughput. Further, the articles sorted to eitherside of the conveyor are directed towards a common tote. Thus,substantially fewer totes are required for the sorting system of thepresent invention, which results in greater efficiency and utilizationcompared to conventional systems.

[0011] In particular, the present invention provides a sorting systemcomprising a conveyor, such as a continuous conveyor belt, thattransports articles along a path of travel. The conveyor can be one ofmany conventional conveyors that are known in the art, and in oneembodiment the conveyor includes an external surface having a pluralityof raised portions, such as cleats, extending therefrom so that articlesplaced on the conveyor can be easily directed off the conveyor. At leastone pair of opposing chutes are positioned along the conveyor that aresized for receiving the articles. Advantageously, the chutes are incommunication with one another, so that articles directed into eitherchute are directed towards a common discharge end. In one embodiment,the common discharge end includes a discharge wall that is in selectivecommunication with the chutes and can be pivoted or positioned from adischarge position to a storage position, as discussed below.

[0012] The sorting system of the present invention also includes asorting device having a paddle for directing the articles from theconveyor to the chutes. More specifically, the paddle includes a firstside and a second side that are operable to engage the articles so thatthe articles are directed from the conveyor to a respective chute. Inone embodiment, the paddle includes a brush that can be in contact withthe conveyor to ensure that particular articles, such as small, thin, orflat articles, are directed or swept off the conveyor into the chutes.The brush is particularly useful in combination with the cleatedexternal surface of the conveyor, as the brush conforms to the surfaceof the conveyor and thereby ensures that these articles as well ascylindrical, round, and irregularly articles are directed from theconveyor. Advantageously, the paddle of the present invention can directarticles from either side of the conveyor without returning to aninitial position between directing consecutive articles. In this manner,the sorting system of the present invention allows for substantiallygreater throughput than conventional systems.

[0013] The sorting device also includes a drive source for directing thepaddle into engagement with the articles. In a presently preferredembodiment, the drive source is a pneumatic device that is operablyconnected to the paddle and which directs the paddle between a firstposition and a second position quickly and precisely. The drive sourceis operably connected to a detector, which detects the presence of anarticle at a particular point along the path of travel. The term“detector” is meant to be interpreted broadly, and preferably comprisesa light-detecting device, such as a photocell, bar-code reader, or acolor-code reader, that is known in the art.

[0014] As mentioned above, the pair of chutes according to the presentinvention are positioned across the conveyor from one another and are incommunication with a common discharge end. More specifically, the chutesare preferably positioned opposite one another along the path of travelso that articles can be directed from the conveyor by the paddle.However, the chutes do not have to be directly opposite one another, aslong as the chutes remain in communication with one another and have acommon discharge end. According to a presently preferred embodiment, thecommon discharge end includes a pivotable discharge wall that ispivotable between a discharge position and a storage position. Anactuator, such as a pneumatic or hydraulic piston, is preferablyprovided for moving the discharge wall between the discharge positionand the storage position.

[0015] In one embodiment, a cover layer is attached to at least one ofthe chutes for assisting in directing the articles to the commondischarge end. The cover layer is preferably formed of a low-friction,polymeric material and extends substantially the length of the chute. Inthis regard, the cover layer provides a relatively smooth path for thearticles as they move towards the discharge end.

[0016] Associated methods are also part of the present invention.According to one method of the present invention, a method of sorting anarticle from a conveyor is provided comprising directing or transportingthe article along a path of travel, detecting the article at a pointalong the path of travel, and directing the article from the conveyor toone of a pair of opposing chutes. As described above, the chutes are incommunication with one another and have a common discharge end.Advantageously, the method provides a simple process for rapidly sortingitems with fewer components, which increases line throughput.

[0017] Another method of sorting articles from a conveyor is providedcomprising directing articles along a path of travel and directing afirst article through a first chute to a tote by engaging the articlewith a first side of a paddle. In particular, the paddle moves from afirst position to a second position in order to direct or sweep thearticle from the conveyor. The method also includes directing a secondarticle along a second chute to a tote by engaging the article with thesecond side of the paddle, wherein the paddle moves from the secondposition to the first position. In one embodiment, the first article andthe second article are directed into the same tote.

[0018] Accordingly, and as is explained in more detail below, thepresent invention provides a system and methods for sorting articlesfrom a conveyor that overcomes the disadvantages of conventional sortingsystems. The present invention is particularly advantageous for sortingsmall articles, such as nail polish bottles, combs, toothbrushes, andsmall electronics. The new system provides fast and efficient sorting byutilizing a single paddle or paddle to sort articles off either side ofthe conveyor, which allows for significantly increased throughputcompared to conventional systems. Further, the new system directsarticles from either chute to a common discharge end so that articlessorted from either side of the conveyor can be directed to the sametote, which significantly reduces complexity and improves efficiency.

BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Having thus described the invention in general terms, referencewill now be made to the accompanying drawings, which are not necessarilydrawn to scale, and wherein:

[0020]FIG. 1 is a perspective view of a conveyor sorter system accordingto one embodiment of the present invention;

[0021]FIG. 2 is a end elevational view of a conveyor sorter systemaccording to the present invention;

[0022]FIG. 3 is a side elevational view of a conveyor sorter systemaccording to the present invention;

[0023]FIG. 4 is a top elevational view of a conveyor sorter systemaccording to the present invention;

[0024]FIG. 5 is a greatly enlarged cross-sectional view of a portion ofa conveyor sorter system taken along lines 5-5 of FIG. 4; and

[0025]FIG. 6 is a greatly enlarged end view of a portion of a conveyorsorter system according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0026] The present invention now will be described more fullyhereinafter with reference to the accompanying drawings, in whichpreferred embodiments of the invention are shown. This invention may,however, be embodied in many different forms and should not be construedas limited to the embodiments set forth herein; rather, theseembodiments are provided so that this disclosure will be thorough andcomplete, and will fully convey the scope of the invention to thoseskilled in the art. Like numbers refer to like elements throughout.

[0027] Referring first to FIGS. 1-4, a new conveyor sorting system 10 isprovided by the present invention for quickly and efficiently sortingitems from a conveyor to a desired location, such as a bin, storagetote, or downstream conveyor. In particular, the system 10 comprises aconveyor 12, such as a continuous conveyor belt defining a pair ofopposing sides, that is supported by rails 13 so that the conveyortravels along a predetermined path. In most cases the predetermined pathwill be rectilinear, although the path may also comprise curves andbends depending on the particular needs of the system. The conveyor 12is operable to transport or direct articles of various shapes and sizesalong a path of travel defined by the conveyor. The system 10, however,is particularly advantageous for sorting uniquely shaped articles, suchas nail files, toothbrushes, small electronics, cylindrical tubes andthe like. These articles are typically thin or flat, or may have atendency to roll, and have been shown to be particularly difficult tosort using conventional systems and methods. The present system 10,however, is designed to easily sweep or sort these articles from theconveyor 12, as explained more fully below.

[0028] The conveyor 12 is a plastic, rubberized, or coated belt thatprovides sufficient friction with articles placed thereon, and as shownin FIGS. 1 and 4 can include a plurality of raised portion or cleats 24that are defined by the outer surface 23 of the conveyor. The cleats 24can have a rectilinear or curved shape, and the cleats extend across theconveyor 12 generally perpendicular to a predetermined path of traveland define a plurality of valleys 25 (FIG. 5) between the cleats. Inthis regard, the cleats 24 can support large or, thin articles above thevalleys 25 so that the articles can be more easily removed. In addition,the cleats 24 provide support boundaries for smaller articles or roundedarticles, such as shampoo, hairspray, or medicine bottles, that mayotherwise roll off the conveyor 12.

[0029] The system 10 also includes a sorting area 14 positioned alongthe predetermined path. In a presently preferred embodiment, the sortingarea 14 includes a “V”-shaped outer housing 16 that is connected to therails 13 and a plurality of external supports 18 such that the sortingarea at least partially surrounds the conveyor 12. More specifically,the outer housing 16 includes a front wall 17, a rear wall 19, sidewalls 61 and lower walls 64. In one embodiment, the lower walls 64converge at an angle X to form the lower portion of the “V” shape. AngleX can be in the range of about 5-60° from horizontal, and preferably isabout 30°.

[0030] The sorting area 14 also includes a plurality of dividers 20 thatare disposed at spaced intervals along the predetermined path of theconveyor 12 between the front wall 17 and the rear wall 19. In oneembodiment, the dividers 20, the front wall 17, and the rear wall 19 allhave a generally “V” shape for ease of manufacturing and appearance,although this is not required. Preferably, the dividers 20 extend fromthe rails 13 supporting the conveyor 12 to the inner surface 62 of theside walls 61 and the inner surface 65 of the lower walls 64 to define aplurality of bins or chutes 22 adjacent the conveyor. More specifically,the chutes 22 are divided into opposing pairs of chutes comprising afirst chute 66 and a second chute 68 that define inlets defined by thedividers 20 (or the front wall 17 or rear wall 19 depending on thelocation of the chutes), the inner surface 62 of the side walls 61, theinner surface 65 of the lower walls 64, and the rails 13. Thus, articlesbeing directed from the conveyor 12 fall into either the first chute 66or second chute 68. Advantageously, the first chute 66 and second chute68 define outlets that are in communication with one another so thatarticles sorted into either the first chute or the second chute aredirected toward a common point or intersection 58 formed by theconverging lower walls 64.

[0031] The sorting area 14 also includes a plurality of sorting devices30 that are preferably attached to the housing 16 and positioned abovethe conveyor 12 such that the number of sorting device 30 corresponds tothe number of pairs of opposing chutes 22 spaced along the predeterminedpath. In particular, each sorting device 30 includes an upper member 32that is positioned substantially perpendicular to the predetermined pathand is connected to the housing 16, such as by a nut and boltcombination or similar fastener. In addition, vibration dampeners 31(see FIGS. 4 and 5) can be added as well where the upper member 32 isattached or connected to the housing 16. In one embodiment, the uppermember 32 includes a piston 36 that is slidably connected to a supportchannel 33 defined by the upper member, as discussed below.Alternatively, the support channel 33 could be a separate piece from theupper member 32.

[0032] The sorting device 30, which is preferably a “rodless cylinder”or “band cylinder” that can be commercially purchased, also includes ashuttle 38 that is attached to the piston 36 so that both the shuttleand piston are movable across the conveyor 12. More specifically, thepiston 36 is connected to the shuttle 38 through a slot (not shown)running the length of the support channel 33. A seal, such as a rubberseal, is disposed in the slot so that the slot is closed except wherethe piston 36 and shuttle 38 attach. The piston 36 is controlled by adrive source 34, which can be pneumatic, hydraulic, mechanical,electrical, or other type of drive source known in the art. In apresently preferred embodiment, the drive source 34 is a high-pressureair source that is operably connected to and in selective communicationwith the piston 36 via a valve 35 that is positioned in the supportchannel 33. In this regard, the drive source 34 is operable to move thepiston 36 and the shuttle 38 across the conveyor 12. In addition,vibration mounts 39 are positioned adjacent the shuttle 38 to limitunwanted movement of the shuttle. Although the shuttle and drive sourceaccording to one embodiment of the present invention have been shown anddescribed, many other types of drive systems known in the art could beused, such as those used with conventional air cylinders with externalcarriages.

[0033] As shown best in FIG. 5, the sorting device 30 also includes asingle plow or paddle 40 that is connected to the shuttle 38 and extendstherefrom towards the conveyor 12. The paddle 40 is preferably formed ofa rigid or semi-rigid material, such as plastic or metal, and in oneembodiment includes a brush 42 at a distal end 41 for improving thecontact between the paddle and the conveyor 12. In a presently preferredembodiment, the brush 42 includes a plurality of bristles formed from apolymeric material, although other material, such as natural fibers,could also be used. Accordingly, the paddle 40 is capable of directingarticles from the conveyor 12 into the chutes 22. Advantageously, thepaddle 40 includes a first surface 43 and a second surface 44 that caneach be utilized for engaging the articles and sweeping or directing thearticles into the first chute 66 and the second chute 68, respectively.As shown, the first surface 43 and the second surface 44 aresubstantially planar, although the surfaces can be of other shapes, suchas contoured, curved, etc., in order to assist with engagement of thearticles. In this manner, the shuttle 38 is operable to sort articlesfrom either side of the conveyor 12, which greatly improves thethroughput capacity of the system 10 compared to conventional sortingsystems since the articles can be spaced closer together on theconveyor.

[0034] For example, in a hypothetical conventional system having asingle-sided pusher, articles must be spaced about 24 inches apart alongthe predetermined path of the conveyor so that the pusher can push anarticle off the conveyor and have time to return to its initial positionso that the next pushing action can be performed. By contrast, theshuttle 38 of the present invention does not have to return to aninitial position between each pushing or directing action, so thatarticles can be spaced closer together on the conveyor 12. In the aboveexample with all other factors being equal, articles could be spaced 12inches apart or less, which effectively doubles the throughput of thesystem 10 at any given conveyor speed.

[0035] The system 10 also includes a detector 48 that is operablyconnected to the sorting device 30. The detector 48, which can be one ofmany types of detectors known in the art, such as a light-detectingdevice or photocell, bar-code reader, or similar device, detects thepresence of an article or the presence of a “sort” indicator and relaysan appropriate signal to a processor (not shown) that controls the drivesource 34 and thus the piston 36 and shuttle 38. In one embodiment, thedetector 48 can also emit a beam that is designed to be broken by thepresence of an article. When the beam is broken, the detector sends anappropriate signal to the processor for determining whether a sortingaction is required by the sorting device 30. In another embodiment, thedetector 48 is a bar-code reader that is operable to read a bar-codeplaced on an article itself or on the conveyor 12 corresponding to thearticle, and relay the information to the processor for determining if asorting action is required. In yet another embodiment, the detector, 48is a color-code detector operable to detect color that is present on anarticle or, preferably, on the surface of the conveyor 12 correspondingto the article. In this embodiment, the conveyor 12 includes at leastone colored region 50 (FIG. 4) that is correlated or assigned to aparticular product, such that the sorting action for the product isdetermined based on the color detected by the detector 48.

[0036] As mentioned above, the system 10 includes a plurality ofopposing chutes 22 spaced along the predetermined path of travel. Theterm “opposing” is meant to be interpreted broadly, such that the firstchute 66 and the second chute 68 do not have to be parallel with oneanother in respect to the predetermined path, as long as the first andseconds chutes are in communication with one another. As shown best inFIGS. 1, 3, and 6, each pair of chutes 22 defines a common discharge end70 for allowing the articles sorted into the first chute 66 and thesecond chute 68 to be directed to a desired location, such as a storagebin, tote, or downstream conveyor. In this regard, the first chute 66defines an opening 86 in the lower wall 64 extending a distance D fromthe intersection 58 of the lower walls of the first chute and the secondchute 68 to a point along the lower wall of the first chute. The opening86 may also extend substantially the width of the first chute 66 definedas the distance between the dividers 20 (or between a divider and eitherthe front wall 17 or the rear wall 19 in the case of the outermostchutes), although this is not required. In addition, the shape of theopening 86 can be of any shape sufficient to allow articles to passtherethrough, and can include beveled or sloped surfaces to facilitateeasier passage into the opening.

[0037] The sorting area 14 also includes a discharge wall 71 that ismovably or pivotally connected to the housing 16 at the intersection 58of the converging lower walls 64 by a hinge 72 or similar device. Thedischarge wall 71 is preferably planar and is sized to cover the opening86 defined by the first chute 66. The discharge wall 71 is pivotablebetween a discharge position 80 and a storage position 81.Alternatively, the discharge wall 71 may be selectively pivotablebetween a plurality of elevations to allow products or articles to fallinto specific totes. To facilitate movement of the discharge wall 71, anactuator 78 is connected to a pair of brackets 74, 76 extending from thelower wall 64 of the second chute 68 and the discharge wall 71,respectively (see FIG. 6). The actuator can be one of many actuatorsknown in the art, and is preferably a hydraulic or pneumatic actuator,such as a pneumatic cylinder actuator manufactured by SMC Pneumatics ofIndianapolis, Ind. Other types of actuators can also be used, such aselectromechanical linear actuators or linear solenoids. The actuatorcould also be a bias member, such as a spring. The discharge wall 71 canbe positioned in other ways as well. For example, the discharge wallcould be pivotally connected at the top of the opening 86 instead of atthe intersection 58 of the lower walls 64. Alternatively, the dischargewall 71 can be stationary or completely removed to expose the opening86.

[0038] When the discharge wall 71 is in the discharge position 80, thedischarge wall forms a pathway in communication with the first chute 66and the second chute 68 so that articles can be directed from the chutesto a desired location, such as a tote 90 shown in the Figures. Inparticular, the pathway formed by the discharge wall allows articlesdirected into the second chute 68 to slide or tumble through the chuteand opening 86, and down the discharge wall 71 into the tote 90.Similarly, articles directed into the first chute 66 slide or tumblethrough the chute and fall through the opening 86 defined therein to thedischarge wall 71 and tote 90. In this regard, the discharge end 70 iscommon to both the first chute 66 and the second chute 68.

[0039] The discharge wall 71 can also be pivoted to the storage position81, which acts to hold or store any articles that are directed into thechutes 66, 68 while the discharge wall is in the storage position. Inparticular, the discharge wall 71 covers the opening 86 when thedischarge wall is in the storage position so that articles cannot escapeor be directed to the tote 90. This feature is particularly advantageouswhen the tote 90 becomes full or when a desired number of articles havebeen sorted to the tote, because the sorting action of the system 10 cancontinue while one tote is exchanged for another tote. During this timethe discharge wall 71 remains in the storage position 81 and articlesare collected in the chutes. When the new tote is ready, the dischargewall 71 can be pivoted to the discharge position 80 so that articlesstored in the chutes are released to the tote. The actuator 78 thatcontrols the pivoting operation of the discharge wall 71 can be manuallyoperated, such as by an operator-controlled switch, or can beautomatically controlled, such as by the processor described above.

[0040] To facilitate easy transfer of the articles through the chutes, aliner 88 is attached to the first chute 66 and the second chute 68. Theliner 88 preferably is formed of a flexible polymeric material, such aswoven nylon or polyester, having a low coefficient of friction. Theliner 88 could also include padding (not shown), such as foam, toprevent fragile products from being damaged as they travel through thechute. In one advantageous embodiment shown in FIG. 2, the liner 88attached to the second chute 68 extends along the discharge wall 71 aswell so that articles can easily slide or tumble along the liner to thetote 90.

[0041] As described above, the discharge end 70 is operable to directarticles to a desired location, such as to the tote 90. FIG. 2 shows anend view whereby several totes are spaced proximate the sorting area 14along the predetermined path so that each tote corresponds to arespective discharge end 70. In particular, the tote 90 is positionedadjacent the respective discharge end 70 such that when the dischargewall 71 is in the discharge position 80 the tote is in communicationwith the chutes 66, 68. Advantageously, the system 10 of the presentinvention requires only half as many totes per sorting action asconventional systems since the opposing first and second chutes 66, 68share the discharge end and tote 90. In addition, the discharge ends arepositioned in an alternating pattern along the predetermined path sothat the tote size can be about 1.5 times the width of the chutes, whichimproves efficiency. It is also beneficial to alternate the dischargeends in order to avoid the external supports 18 of the housing 14.However, the system 10 can also be designed to include discharge endsonly on one side or directly below the conveyor 12.

[0042] In one embodiment, the sorting area 14 also includes a take-awayconveyor 46 positioned below the conveyor 12 for transporting totes to adesired location. For example, when the tote 90 is full, it can beplaced on the take away conveyor 46, which can be a continuous belt-typeconveyor, roller conveyor, or the like, and directed to a downstreamlocation, such as a shipping department, inspection area, or furtherprocessing station.

[0043] In operation, articles are placed on the conveyor 12 and theconveyor is set in motion such that the articles are directed along apath of travel corresponding to the predetermined path. At apredetermined point along the path of travel, such as when the articleis proximate a sorting device 30, the presence of the article isdetected by the detector 48 in a manner described above or a similarmanner thereto. The signal from the detector 48 is sent to theprocessor, which determines whether a sorting action is required for theparticular article. If the processor determines that the article is notto be sorted, the sorting device 30 receives no signal or a “hold”signal from the processor such that the shuttle 38 remains on a first orinitial side of the support channel 33 and thus does not move across theconveyor 12.

[0044] If the article is to be sorted into a tote, however, theprocessor sends a signal to the drive source 34 such that the piston 36and shuttle 38 are moved along the support channel 33. In this manner,the paddle 40 connected to the shuttle 38 engages the article anddirects the article from the conveyor 12 into either the first chute 66or the second chute 68. When the sorting action is complete, the shuttle38 stops at a second position, such as at one end of the support channel33 across the conveyor 12 from the first position of the shuttle.Advantageously, the shuttle 38 and paddle 40 are ready to immediatelyengage the next detected article. If it is determined that the nextdetected article is to be sorted by the same sorting device 30, a signalis sent from the processor as described above to the sorting device 30so that the shuttle 38 is directed back across the support channel 33from the second position to the first position to direct the article offthe conveyor 12 into the adjacent chute. The process can then berepeated for as long as it is determined that articles are to be sortedby that particular sorting device. Advantageously, all of the articlesdirected to either chute associated with the sorting device are directedto the same discharge end.

[0045] As mentioned above, the detector 48 can be a color-reading deviceused in conjunction with color-coded articles or a colored portion orregion 50 on the conveyor 12. To illustrate this embodiment, a specifictype of article, such as combs, can be assigned to and placed on aparticular colored portion or region 50 of the conveyor 12, such as agreen colored region. The colored region 50 is located on the conveyor12 so that it is visible to the detector 48. As the conveyor 12 movesthe combs along the predetermined path of travel, the detector 48detects the colored region 50 of the conveyor and relays a signalcorresponding to that particular color (green, in this example) to theprocessor. The detector 48 may also be used with another detector, suchas a photocell, so that the colored region of the conveyor as well asthe article itself are detected. The processor then determines if thatsorting device 30 is designated to sort items assigned to the greencolored region of the conveyor. If yes, the processor sends anappropriate signal as described above to the sorting device 30 via thedrive source 34 to sort or direct the items corresponding to thatparticular color off the conveyor 12 and into the chutes.Advantageously, the paddle 40 of the sorting device 30 can move acrossthe conveyor 12 to direct consecutively spaced articles into the firstand second chutes 66, 68 toward the common discharge end 70. As such,articles can be sorted off either side of the conveyor 12 and bedirected to the same tote 90 by the paddle 40 of a single sorting device30, which allows for greater throughput and efficiency.

[0046] As shown in the Figures, the system 10 of the present inventioncan include a plurality of sorting devices and detectors. In thisregard, each detector can operate in a manner described above so thatappropriate “sort” signals are sent by the processor to a correspondingsorting device.

[0047] Alternatively, the system 10 may only include a single detectorthat is positioned before the sorting devices 30 and a counter (notshown) operatively connected to the conveyor 12 and processor fordetermining the position of an article along the path of travel. In thisalternatively embodiment the detector 48 detects the presence of thearticle, such as by bar code or color code as described above, and thecounter records the article's position. The processor determines whichsorting device 30 is to sort that particular article, and the countercommunicates with the processor so that the paddle 40 of thecorresponding sorting device is moved across the conveyor 12 when thearticle is in a position to be swept. For example, suppose an articledetected by the detector 48 is determined by the processor to be sortedat the third sorting device, and that the third sorting device is 150counts by the counter from where the article is detected. In thisexample, the processor causes the third sorting device to sweep thearticle from the conveyor 12 when the counter reaches 150 counts fromwhen the article was detected. This process can be performed for theremaining articles detected on the conveyor 12 so that each article isdetected by the detector 48, and the processor, counter, and sortingdevices communicate with one another to sweep the articles from theconveyor at the desired locations.

[0048] Thus, the sorting system 10 of the present invention is capableof sorting different articles to different totes as the articles aretransported by the conveyor. In the following examples, which are forillustration purposes only, several different items, such as lipstick,shampoo, combs, and small boxes are desired to be sorted intocorresponding totes, which receive the articles to fulfill customers'orders. In the first example, Customer Order #1 is for ten lipsticks,Customer Order #2 is for six shampoos, and so on. Sorting DeviceDesignated Color Article Quantity 1 red lipstick 10 2 yellow shampoo 6 3blue small box 12 4 green comb 4 5 red lipstick 3

[0049] In this example, the articles are arranged by operators or bymachine on the corresponding colored regions 50 of the conveyor 12 andmoved down the predetermined path of travel. When the articles arrive atthe first sorting device, ten lipsticks will be sorted into the chutesand the tote corresponding to the first sorting device. In particular,the processor is programmed to determine how many sorting operations arerequired by each sorting device, and the processor counts and controlseach sorting action accordingly. Note that the shampoo will not besorted by the first sorting device, as the first sorting device onlysorts articles associated with the designated color red. Instead, thesecond sorting device sorts six shampoos to the corresponding chutes andtote. The process is similar for the third and fourth sorting devices.The fifth sorting device is also designated to sort articles associatedwith the color red. In this regard, the fifth sorting device willreceive articles to sort after the first sorting device has fulfilledits requirement of ten articles. Alternatively, the system could bedesigned so that both the first and fifth sorting devices receivearticles to sort. This may be advantageous where the first and fifthsorting devices sort the same article for different customers and it isdesirable to fulfill both orders simultaneously.

[0050] In the second example, Customer Order #1 is for one lipstick, twocombs, and ten small boxes. In this example, the processor causes thefirst sorting device to sort these items off one or both sides of theconveyor 12 into the first tote. When the items have been sorted intothe tote, the tote can then be directed to downstream processing, or thesorted items can be removed from the tote and further processed tofulfill the order.

[0051] As has been shown and described, the system 10 and methods of thepresent invention overcome the disadvantages of conventional systems byproviding a sorting system that is fast and efficient by providing asorting device 30 having a single paddle 40 for sorting articles offeither side of a conveyor toward a common discharge end 70. In thisregard, the articles are sorted into one of a pair of opposing chutes66, 68 that are in communication with one another that allow articles tobe directed to a tote 90 via the discharge wall 71 of the discharge end70. In addition, the system 10 provides at least one detector 48 fordirectly or indirectly detecting the presence of an article and sendingsignals to a processor for determining sorting actions by the sortingdevice. The system and methods of the present invention allow for morethroughput and speed, which results in a more efficient sorting process.

[0052] Many modifications and other embodiments of the invention willcome to mind to one skilled in the art to which this invention pertainshaving the benefit of the teachings presented in the foregoingdescriptions and the associated drawings. For example, the system 10could avoid providing a discharge wall, but may rather position theopening at the intersection of the lower walls such that articles sortedinto the chutes fall through the opening to a tote, conveyor, or otherobject. Alternatively, the discharge wall may be in a fixed position anda release wall may be provided for sliding over the opening to open thedischarge end. Therefore, it is to be understood that the invention isnot to be limited to the specific embodiments disclosed and thatmodifications and other embodiments are intended to be included withinthe scope of the appended claims. Although specific terms are employedherein, they are used in a generic and descriptive sense only and notfor purposes of limitation.

That which is claimed:
 1. A sorting system for sorting articles ofdifferent types, the system comprising: a conveyor for transporting thearticles along a path of travel, said conveyor defining a pair ofopposing sides; a detector positioned proximate said conveyor fordetecting the presence of the articles; a pair of opposing chutesdefining inlets adjacent said opposing sides of said conveyor; and atleast one paddle having a first side and a second side, said paddlebeing in operative communication with said detector such that both ofsaid sides of said paddle are operable to engage articles and directarticles into either inlet of said pair of opposing chutes.
 2. A sortingsystem according to claim 1, wherein said pair of opposing chutesfurther defines outlets in communication with one another that combineand define a common discharge end.
 3. A sorting system according toclaim 1, further comprising a drive source operably connected to said atleast one paddle for directing said at least one paddle into engagementwith the article being transported by the conveyor.
 4. A sorting systemaccording to claim 3, wherein said drive source is a pneumatic drivesource.
 5. A sorting system according to claim 3, wherein said drivesource is a hydraulic drive source.
 6. A sorting system according toclaim 3, wherein said drive source is an electric drive source.
 7. Asorting system according to claim 1, wherein at least one of said firstside and said second side of said paddle has a surface complimentary tothe articles.
 8. A sorting system according to claim 1, wherein said atleast one paddle includes a brush at one end thereof.
 9. A sortingsystem according to claim 1, wherein said conveyor includes an externalsurface having a plurality of raised portions extending therefrom.
 10. Asorting system according to claim 1, further comprising a cover layerattached to at least one of said pair of opposing chutes.
 11. A sortingsystem according to claim 10, wherein said cover layer extends over atleast a portion of said at least one of said pair of opposing chutes.12. A sorting system for sorting articles of different types, the systemcomprising: a conveyor for transporting the articles along a path oftravel, said conveyor defining a pair of opposing sides; a pair ofchutes defining inlets adjacent said opposing sides of said conveyor; adischarge wall movably attached to at least one of said pair of opposingchutes, said discharge wall movable at least between a dischargeposition and a storage position; and at least one paddle having a firstside and a second side, said paddle being operable to engage articlesand direct articles into either inlet of said pair of opposing chutes.13. A sorting system according to claim 12, wherein said pair ofopposing chutes further defines outlets in communication with oneanother that combine and define a common discharge end.
 14. A sortingsystem according to claim 12, wherein said at least one paddle includesa brush at one end thereof.
 15. A sorting system according to claim 12,wherein said conveyor includes an external surface having a plurality ofraised portions extending therefrom.
 16. A sorting system according toclaim 12, further comprising an actuator operable to move said dischargewall between the discharge position and the storage position.
 17. Amethod of sorting an article from a conveyor, comprising: directing thearticle along a path of travel with the conveyor; detecting the presenceof the article at a point along the path of travel; and directing thearticle from the conveyor to one of a plurality of opposing chutes, thechutes being in communication with one another and having a commondischarge end.
 18. A method according to claim 17, wherein detecting thepresence of the article comprises detecting a bar code.
 19. A methodaccording to claim 17, wherein detecting the presence of the articlecomprises detecting a breach of a light beam.
 20. A method according toclaim 17, wherein detecting the presence of the article comprisesdetecting light values corresponding to color.
 21. A method according toclaim 17, wherein directing the article from the conveyor comprisesengaging the article with a paddle having a first side and a secondside, the first side and the second side each being capable of directingthe article to a respective chute of said plurality of opposing chutes.22. A method of sorting an article from a conveyor, comprising:directing the article along a path of travel with the conveyor;detecting the presence of the article at a point along the path oftravel; directing the article from the conveyor to one of a plurality ofopposing chutes being in communication with one another and having acommon discharge end; and selectively positioning a discharge wallproximate the common discharge end between a discharge position and astorage position.
 23. A method of sorting an article from a conveyor,comprising: directing the article along a path of travel with theconveyor; detecting the presence of the article at a point along thepath of travel; directing the article from the conveyor to one of aplurality of opposing chutes being in communication with one another andhaving a common discharge end; and directing the article to a storagetote.
 24. A method of sorting an article from a conveyor, comprising:directing the article along a path of travel with the conveyor;detecting the presence of the article at a point along the path oftravel; directing the article from the conveyor to one of a plurality ofopposing chutes being in communication with one another and having acommon discharge end; and storing the article in the pair of chutes fora predetermined interval.
 25. A method of sorting articles from aconveyor, comprising: directing the articles along a path of travel withthe conveyor; directing a first article to a first chute by engaging thefirst article with a first side of a paddle, the paddle moving from afirst position to a second position; and directing a second article to asecond chute by engaging the second article with a second side of thepaddle, the paddle moving from the second position to the firstposition.
 26. A method according to claim 25, wherein the first articleis directed into a tote and the second article is directed into a tote.27. The method according to claim 25, wherein the first article and thesecond article are directed into the same tote.
 28. A sorting system forsorting uniquely shaped articles, the system comprising: a conveyor fortransporting the articles along a path of travel, said conveyor definingan external surface with a plurality of raised portions and a pluralityof valleys between the raised portions, the raised portions being spacedapart to support the uniquely shaped articles; a sorting devicepositioned proximate said conveyor, said sorting device operable to movesubstantially perpendicular to the path of travel of the conveyor; atleast one paddle having a proximal end connected to the sorting device,and a distal end; and a brush extending from the distal end of the atleast one paddle, said brush operable to substantially contact both theraised portions and the valleys of the conveyor when said sorting devicemoves substantially perpendicular to the path of travel of the conveyor,so as to push the uniquely shaped articles from the conveyor.
 29. Asorting system according to claim 28, wherein said conveyor is formedfrom a polymeric material.
 30. A sorting system according to claim 28,wherein said brush includes a plurality of bristles formed from apolymeric material.